cashco CA1, SA1 Installation, Operation & Maintenance Manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM)

ISO Registered Company

IOM-CA1/SA1

MODEL CA1/SA1

CA1 and SA1 - ULTRA HIGH PURITY, SPRING LOADED

PRESSURE REDUCING REGULATORS

SECTION I

I. DESCRIPTION AND SCOPE

Models CA1/SA1 are pressure reducing regulators used to control downstream (outlet or P2) pressure. Sizes are
3/4" (DN20), 1" (DN25), 1-1/2" (DN40), and 2" (DN50). With proper trim uti li za tion, the unit is suitable for liquid or
gaseous service. (NOTE: This product was formerly identified as a Model C1 or S1; a Model CA1/SA1 and C1/S1

are one and the same product.)

SECTION II

II. REFERENCES

Refer to Technical Bulletin CA1/SA1-TB for tech ni-

cal specifications of a Model CA1/SA1 reg u la tor.

CCW – Counter Clockwise
CW – Clockwise
ITA – Inner Trim Assembly

ABBREVIATIONS

12-16

CAUTION

Installation of adequate overpressure pro tec tion
is recommended to pro tect the reg u la tor and all
downstream equip ment from dam age in the event
of reg u la tor failure.

III. INSTALLATION

1. Install per direction of flow arrow indicated on
body, or "IN" and "OUT" markings.

2. Regulator may be rotated around pipe axis 360
degrees. For ease of maintenance, the rec om­ mend ed orientation is with the spring chamber
(4) upwards.

3. Provide space below, above, and around reg u la tor
for removal of parts during maintenance.

4. Install block valves and pressure gauges to pro­ vide means for adjustment, operation, bypass, or
removal of the regulator. A UHP filter is rec om­ mend ed before inlet to remove typical pipe line
debris from entering valve and damaging internal
“soft goods”, primarily the dynamic seal and valve
seat.

SECTION III

CAUTION

DO NOT HYDROSTATIC TEST THROUGH AN
IN STALLED UNIT; ISOLATE REGULATOR FROM
TEST. The upper range spring pres sure level
on the nameplate is the rec om mend ed “upper
op er at ing limit” for the sens ing di a phragm.
Higher pres sures could cause internal dam age.
In ad di tion, note on the nameplate that the Inlet
and Outlet pres sure and temperature ratings are
at different levels.

IV. PRINCIPLE OF OPERATION

SECTION IV

1. Movement occurs as pressure variations register
on the diaphragm. The registering pressure is the
outlet, P2, or downstream pressure. The range
spring op pos es di a phragm movement. As outlet
pressure drops, the range spring pushes the di a­ phragm down, opening the port; as outlet pres sure

V. STARTUP

1 Start with the block valves closed.

2. Relax the range spring by turning the ad just ing
screw (1) CCW (viewed from above) a minimum
of three (3) full rev o lu tions. This reduces the outlet
(down stream) pres sure set point.

3. If it is a “hot” piping system, and equipped with
a bypass valve, slowly open the bypass valve
to preheat the system piping and to allow slow
ex pan sion of the piping. Closely monitor outlet
(down stream) pressure via gauge to ensure not
over-pressurizing. NOTE: If no bypass valve is

in stalled, extra caution should be used in start ing
up a cold system; i.e. do everything slowly.

CAUTION

Do not walk away and leave a bypassed reg u la tor
unattended!

4. Crack open the outlet (downstream) block valve.

5. Slowly open the inlet (upstream) block valve to
about 25% open, observing the outlet (down­ stream) pres sure gauge. Determine if the reg u­ la tor is flowing. If not, slowly rotate the regulator
ad just ing screw (1) CW (viewed from above) until
flow be gins.

increases, the diaphragm pushes up and the port
opening closes.

2. A complete diaphragm failure will cause the reg u­ la tor to fail open and fluid will discharge from the
spring chamber vent hole.

SECTION V

6. Continue to slowly open the inlet (upstream) block
valve until fully open.

7. Continue to slowly open the outlet (downstream)
block valve, especially when the downstream pip­ing system isn’t pressurized. If the outlet (down­ stream) pressure exceeds the desired pres sure,
close the inlet block valve and go to Step 2. Close
bypass valve approximately 25%, and re peat
pro ce dure.

8. When flow is established steady enough that the
outlet (downstream) block valve is fully open, begin
to slowly close the bypass valve if installed.

9. Develop system flow to a level near its expected
normal rate, and reset the regulator set point by
turning the adjusting screw (1) CW to increase
outlet pressure, or CCW to reduce outlet pres sure.

10. Reduce system flow to a minimum level and ob­serve pressure set point. Outlet pressure will rise
from the set point of Step 9. The maximum rise
in outlet pressure on decreasing flow should not
exceed the stated upper limit of the range spring
by greater than 10%. If it does, consult factory.

VI. SHUTDOWN

1. Shutoff inlet block valve.

2. Allow sufficient time for the line pressure down­ stream of the inlet block valve to bleed down.

3. Shutoff the outlet block valve.

2

SECTION VI

4. Relieve the trapped upstream and down stream
pres sure.

5. The regulator may now be disassembled for
inspection and pre ven ta tive main te nance while
in-line.

IOM-CA1/SA1

VII. MAINTENANCE

A. General:

1. The regulator may be serviced without re mov­ ing the regulator from pipeline. The reg u la tor
is designed with quick-change trim to simplify
maintenance.

SECTION VII

ing screw (1) CCW (viewed from above) until
removed from spring cham ber (4).

3. Loosen the diaphragm flange bolts (12) and
nuts (11) uniformly. Remove all bolting.

4. Place matchmarks on body (23) and spring
chamber (4) flanges. Remove the spring
cham ber (4) by lifting vertically.

2. Record the nameplate information to req ui si­ tion spare parts for the regulator. The in for­ ma tion should include: Size, Product Code,
and Serial Number.

3. Refer to Section IX for recommended spare
parts. Only use original equipment parts
sup plied by Cashco for re build ing or re pair ing
regulators.

4. Owner should refer to owner's procedures for
removal, handling, cleaning and disposal of
nonreusable parts, i.e. seals, etc.

5. The Inner Trim is re moved and replaced in the
body (23) as an assemblage of parts. The
Inner Trim Assembly, here in af ter called ITA,
consists of the fol low ing parts:

Item Dynamic
No. Seal Type Part Description

13 ..................... All ..........................Piston-Guide Bearing

15 .....................All ................................ Cage O-ring Seal

16..................... UC.................................................Shim

19 ..................... All ................................................... Cage

20 ..................... All ...........................................Valve Plug

21 ..................... All ............................................ Seat Ring

27 .....................All ............................. Dynamic Side Seal

27.1 .............. CP............................................. Cap Seal

27.2 .............. CP..........................O-ring Energizer/Seal

27.3 .............. UC .......... U-Cup Seal w/Metal Energizer

5. Remove the washers (14), spring follower (5)
and range spring (6).

6. Remove upper diaphragm pressure plate (8).

7. Remove diaphragm(s) (9) and examine to
de ter mine if failed. If diaphragms failed, de­ ter mine if op er at ing con di tions are ex ceed ing
designed pressure or tem per a ture limits.

8. Evenly loosen the three cage cap screws (18)
in single revolution increments. The reg u la tor
con tains a lower return spring (22); the ITA
should rise as the cage cap screws (18) are
backed out evenly. A downward holding force
should be ap plied to the top of the piston-guide
bearing (13) to pre vent the ITA from pop ping
up as the last threads of the cage cap screws
(18) are disengaged. Remove washers (17).

13

19

15

*

27.3

*

16

20

6. A detailed view of the dynamic side seal parts
is shown in Figure 1; an assembled ITA in
Figure 2; and a cross-sectional drawing of
the entire regulator is shown in Figure 3.

WARNING

SYSTEM UNDER PRESSURE. Prior to per form ing
any maintenance, isolate the reg u la tor from the
sys tem and relieve all pressure. Failure to do so
could result in personal injury.

B. Main Regulator Disassembly:

1. Shut down the system in accordance with
Section VI.

2. Loosen adjusting screw lock nut (2) and relax
range spring (6) pressure by turning ad just-

IOM-CA1/SA1

Type UC - U-Cup

Dynamic Seal

27

*

13

19

15

*

27.1

*

27.2

*

16

20

Type CP - Cap

Dynamic Seal

Figure 1: Dynamic Side Seals

3

9. Remove the ITA by pull ing up on the piston­guide bearing (13). Set ITA aside.

10. Remove the lower return spring (22) from
within the body (23).

11. Remove the cage o-ring seal (15).

12. Remove metal C-ring seal (28) from body (23)
di a phragm flange groove.

13. Clean all metal parts to be reused according to
owner's procedures. NOTE: Regulators are

originally supplied with a level of clean li ness
equal to Cashco cleaning standard #S-1662.
Contact factory for details.

C. Disassembly of the ITA:

1. To Disassemble the ITA (See Figure 2):

a. Hold the lower part of the valve plug (20)

in a bench vise; grasp in "smooth jaws"
directly under plug's (20) seating disc por­tion on hub "flats" provided. Do not hold
on the ma chined sur face in the plug's (20)
spin dle area.

e. Remove dynamic side seal (27) com po-

nents and discard. Special care should be
taken when using “tools” to remove the
components to ensure that no scratches
are made to any portion of the piston- guide
bearing (13) groove.

f. Remove the shim (16) from within the

cage (19).

g. Remove seat ring (21); examine for signs

of leakage. If seat ring (21) shows signs of
significant leakage, determine if op er at ing
con di tions - pres sure, pressure drop, or
temperature ex ceed design lim its.

2. Clean all metal parts to be reused according

to owner's procedures. NOTE: Regulators are

originally supplied with a level of clean li ness
equal to Cashco cleaning standard #S-1662.
Contact factory for details.

D. Inspection of Parts:

1. Remove and dis card the fol low ing parts:
o-ring (15), diaphragm(s) (9), seals (27, 28),
and seat ring (21). These parts MUST be
re placed with fac to ry supplied new parts.

16

Figure 2: Assembled ITA, with

"UC" Dynamic Side Seal

b. Using a special double-posted spanner

wrench fitting (to order see NOTE in
Section IX, Parts Ordering Information),
turn the pis ton-guide bear ing (13) CCW
to loosen. The piston-guide bear ing (13)
may be re moved by hand after loos en ing.

c. Remove ITA from vise. Pull the valve plug

(20) down and out through the cage's (19)
bottom opening.

d. Examine the com po nents (27.1, 27.2,

27.3) of the dy nam

ic side seal (27)
mech a nism to de ter mine if sig nif i cant
leakage was oc cur ring. If the dy nam ic
side seal shows signs of sig nif i cant leak­age, de ter mine if op er at ing con di tions
are ex ceed ing pres sure, pres sure drop,
or tem per a ture lim its.

2. Inspect the metal parts that will be reused. The
parts should be free of surface con tam i nants,
burrs, oxides, and scale. Rework and clean
the parts as necessary. Surface con di tions
that affect the regulator performance are stated
below; re place parts that can not be re worked
or cleaned.

3. QC Requirements:
a. Valve plug (20);

1. 16 rms finish on its seating surface
for tight shutoff.

2. No major defects on bottom guide
spin dle.

b. Cage (19);

1. 16 rms finish on cylinder bore. No
“ledg es” formed due to wear from
moving dynamic side seal (27) or plug
(20).

E. Reassembly of the ITA:

1. Installation of dynamic side seal (27) (See
Figure 1):
a. Type CP:

1. Stretch o-ring energizer/seal (27.2)
over low er cir cum fer ence of piston­guide bear ing (13), tak ing care not
to “cut” o-ring energizer/seal. Us ing
thumbs, work the o-ring en er giz er/

4

IOM-CA1/SA1

seal (27.2) into the groove of the
piston-guide bear ing (13).

NOTE: Use NO lubricants!

2. Position cap seal (27.1) ring with
rect an gu lar cross-section at end of
pis ton-guide bearing (13). Stretch cap
seal over lower end of piston-guide
bear ing (13) us ing thumbs to work the
cap seal onto the piston-guide bear­ing. DO NOT USE A TOOL FOR THIS
STEP. Con tin ue pressing cap seal
(27.1) up wards towards the groove
until the cap seal “snaps” into the
groove of the piston-guide bear ing.

3. Insert shim (16) into cage (19) and
al low to rest inside the cage.

4. Position piston-guide bearing (13)
over and into upper end of cage (19)
until the cap seal (27.1) edge touch es
the upper lip of the cage. While gently
applying force to press the piston­guide bearing (13) into the cage (19),
simultaneously use fin gers to lightly
press the cap seal (27.1) in wards into
the groove of the piston-guide bearing
un til the cap seal “slips into” the cage
(19). DO NOT use tools or lu bri cant
to en gage the cap seal (27.1) into the
cage (19). DO NOT press down ward
on pis ton-guide bearing (13) too hard
or fast - the cap seal (27.1) may slide
out of its groove and become dam­ aged.

3. Completion of ITA Reassembly.
a. Insert valve plug (20) upwards through

lower end of cage (19) and through the
center hole of shim (16).

b. Engage valve plug (20) with piston-guide

bearing (13) threads and finger tighten.

c. Place ITA into a vise with smooth jaws

and grasp at hub "flats" location on the
valve plug (20) that is not in the “spindle”
zone. (See Figure 2.)

d. Using a special double-posted spanner

wrench fitting (to order see NOTE in
Section IX, Parts Ordering In for ma tion),
tighten the piston-guide bear ing (13) to
the valve plug (20) with the following
torque values. Do NOT allow valve plug
(20) to rotate against seat ring (21) during
tight en ing.

e. This completes ITA reassembly.

Body Size Ft-lbs. (Nm)
3/4"-1" 40–50 (54–68)
1-1/2"–2" 70–80 (95–108)

F. Main Regulator Reassembly:

1. Insert the return spring (22) into the body (23).

2. Fit cage O-ring seal (15) into the body (23)
groove.

3. With the ITA held manually in the closed po si­ tion, insert ITA and cage (19) into body (23).

2. Place properly oriented seat ring (21) onto its

IOM-CA1/SA1

b. Type UC:

1. Position u-cup seal (27.3) over low er
circumference of piston-guide bear ing
(13). Ensure the u-cup seal is oriented
with the center-open-down wards as
shown in Fig ure 1, as the u-cup seal
de pends upon the P1-Inlet pressure
to activate prop er seal ing ac tion.

2. Insert shim (16) into cage (19) and
al low to rest inside the cage.

3. Position piston-guide bearing (13)
over and into upper end of cage (19)
until the cap seal (27.1) edge touch es
the upper lip of the cage. Gently apply
downward force to press the pis ton­guide bearing (13) into the cage (19).
DO NOT use tools, lu bri cant, or heavy
force to en gage the u-cup seal (27.3)
into the cage.

shoul der at the lower end of cage (19).

4. Properly align all three cage bolt (18) holes as
there is only one proper alignment possible.
Ap ply a down ward force to the top of the
cage (19) until the ITA is lowered suf fi cient ly
to engage the cage bolts (18) with washers
(17) into the body (23). Engage all of the cage
bolts , then tighten the cage bolts in al ter nat ing
one-half rev o lu tion in cre ments to pull down the
ITA evenly. ENSURE THE ITA DOES NOT
BECOME WEDGED AS IT IS SLID INTO
THE BODY. Tight en the cage bolts (18) to a
torque value of 13-15 Ft-lbs (17.5-20.5 Nm).

5. Units with CTFE or VTFE seat ring (21): Due to
the relative "hardness" of the CTFE and VTFE
material, to obtain the best possible shutoff
it is nec es sary to generate a "coined" seating
chamfer.

6. To coin the seat ring:
a. Close-off the outlet connection.
b. The level of seat leakage can be quan ti-

fied at the internal sensing passage.

5

c. Pressurize the regulator's inlet with

50–100 psig (3.5–6.9 Barg) of UHP grade
GN2.

d. Place a thin, flexible membrane that more

than covers the diaphragm flange cavity
of the body (23).

e. Using a soft-headed mallet (rubber,

leath er), sharply rap the thin membrane
over the top,center end of the piston-guide
bear ing (13). (Note: Gas will escape as

the plug (20) is momentarily forced off
the seat ring (21). Allow suf fi cient time
for leak age pres sure on outlet side to
bleed-off.) The ham mer rap should be

strong enough to "bounce" the plug (20)
into the seat ring (21), leav ing a "coined"
seating chamfer. Repeat a minimum of
2 times. Check after each rap to see if
re quired shut off is obtained.

f. After "coining" is complete, remove UHP

grade GN2 pres sure source, membrane
and open out let.

7. To Install Diaphragm(s):
a. Install a new metal C-ring seal (28) into

the body (23) diaphragm flange groove.

b. Center diaphragm(s) (9) onto body's (23)

diaphragm flange.

c. Position upper diaphragm pressure plate

(8) centered on top of diaphragm(s) (9)
with cup upwards.

8. Place a small amount of light lithium grease
onto the adjusting screw (1). Insert both the
ad just ing screw (1) and its lock nut (2) into the
spring chamber (4). Allow the end of adjusting
screw to protrude into interior approximately
1/2 inch (12 mm).

9. Place range spring (6) centered on upper
di a phragm pressure plate (8).

10. Place a small amount of light lithium grease
into the recess of the spring follower (5). In­stall washers (14) on spring follower. Place
the spring follower (5) on upper end of range
spring (6).

11. Aligning matchmarks and bolt holes, place
spring chamber (4) over range spring (6).
If spring chamber flange rests on body (23)
flange without a gap, remove spring chamber
and rotate ad just ing screw (1) deeper into
spring cham ber cavity another 1/4 inch (6
mm). Repeat this pro ce dure until the adjusting
screw (1) keeps the two flanges from touching
by ap prox i mate ly 1/8 inch (3 mm). NOTE: If

flang es do not come to geth er equal ly, the
upper di a phragm pres sure plate (8) may be
off-center. Remove spring cham ber (4) and

reposition upper di a phragm pres sure plate (8)
until the spring chamber comes down evenly
on all sides.

12. Install all flange bolts (12) and nuts (11) with
nameplate (99) located under one bolt head.
Hand-tighten nuts (11).

13. Evenly tighten body bolting (11,12) using an
alternating cross pattern in one revolution
increments. Tighten to the following torque
value: All body sizes: 30-35 Ft-lbs (41-47 Nm).

G. Pressure Testing:

1. If a high static pressure test is performed,
pres sure must be applied to all three of spring
chamber, inlet and outlet of body at the same
level.

DO NOT HIGH STATIC PRESSURE TEST

THE BODY WITH OUT SPRING CHAMBER
PRES SUR IZED. NOT ADHERING WILL DO
PHYSICAL DAMAGE TO INTERNALS THAT
COULD REN DER THE UNIT INOPERABLE.

MAX PRES SURE IS _______ psig (_______Barg).

2. Seat Leakage Test.
a. Release all range spring (6) force by

back ing out adjusting screw (1) fully.

b. Pressurize inlet to 50 psig (3.5 Barg) with

UHP grade GN2.

c. Tube outlet to a beaker of water to ob-

serve number of escaping gas bubbles.
A steady flow of gas bubbles (e.g., 20
bub bles / minute or greater) is ex ces sive
leakage.

3. Excessive leakage will require disassembly,
examination of sealing elements, correction of
problem, reassembly and retesting. Leakage
path may be via plug/seat or dynamic side
seal.

NOTE: If disassembly and re-testing is

required, the metal C-ring seal (28) MUST
be re placed for each disassembly/re as­ sem bly.

6

IOM-CA1/SA1

SECTION VIII

VIII. TROUBLE SHOOTING GUIDE

When trouble shooting this regulator there are many possibilities as to what may be causing problems. Many
times, the regulator itself is not defective, but one or more of the accessories may be. Sometimes the pro cess
may be causing difficulties.

The key to efficient trouble shooting is information and communication. The customer should try to be as precise
as possible in their explanation of the problem, as well as their understanding of the application and operating
con di tions.

It is imperative the following information be provided by the customer:

Fluid (with fluid properties)
Range of flow rate
Range of inlet pressure
Range of outlet pressure
Range of fluid temperature
Range of ambient temperature

Pressure readings should be taken at every location that pressure plays a role - i.e., regulator inlet (as close as
possible to inlet port), regulator outlet (as close as possible to outlet port), etc.

Below are some of the more common complaints along with possible causes and remedies.

1. Erratic regulation, instability or hunting.

Possible Causes Remedies

A. Sticking of internal parts A. Remove internals, clean, and if necessary, replace.

B. Oversized regulator B. Check actual flow conditions; resize regulator for min i mum

and maximum flow; if necessary, replace with smaller
regulator.

2. Downstream pressure will not reach desired setting.

Possible Causes Remedies

A. Supply pressure is down (confiirm
on pressure gauge).

B. Undersized regulator. B. Check actual flow conditions; resize regulator for minimum

3. Diaphragm continually breaks.

Possible Causes Remedies

A. Differential pressure across dia­ phragm may have exceeded limits.
(See Table 1 in Tech Bulletin).

A. Increase supply pressure

and maximum flow; if necessary, replace with larger regulator.

A. Be aware of limits as well as where the various pressures are
acting. Install pressure safety equipment as necessary.
Pressure limit for outlet is lower than the limit of the inlet.

IOM-CA1/SA1

7

4. Leakage at diaphragm flange.

Possible Causes Remedies

A. Body bolts not torqued properly. A1. Torque to proper value (see Section VII, F.13).

A2. Failed C-ring seal. Replace seal.

B. Pressures at diaphragm may be too
high for regulator design.

5. Leakage across seat.

Possible Causes Remedies

A. Contamination (debris) in regulator. A1. Remove internals, clean and if necessary, replace sealing

B. Oversized regulator; plug operates
directly next to seat.

* Excess seat leakage may be diagnosed when a failure of the dynamic side seal has occurred. Inspect both
potential internal leak paths.

C. Failure due to wear. C1. Replace seat.

D. Improper installation. D1. Failure to "coin" CTFE or VTFE seat; disassemble and "coin".

B. Consult factory.

seating elements. *
A2. Install UHP filter at inlet.

B. Check actual flow conditions; resize regulator for minimum and
maximum flow; if necessary, replace with smaller regulator.

C2. Replace all internal trim due wear.

D2. Improper re-assembly. Disassemble and re-assemble per
instructions within IOM.

8

IOM-CA1/SA1

SECTION IX

IX. ORDERING INFORMATION
NEW REPLACEMENT UNIT VS PARTS "KIT" FOR FIELD RE

To obtain a quotation or place an order, please retrieve the Serial Number and Product Code that was stamped on
the metal name plate and attached to the unit. This information can also be found on the Bill of Material ("BOM"),
a parts list that was provided when unit was originally shipped. (Serial Number typically 6 digits). Product Code
typical format as follows: (last digit is alpha character that reflects revision level for the product).

–

NEW REPLACEMENT UNIT:

Contact your local Cashco, Inc., Sales Rep re sen­ ta tive with the Serial Number and Product code.
With this information they can provide a quotation
for a new unit including a complete description,
price and availability.

CAUTION

Do not attempt to alter the original construction
of any unit without assistance and approval from
the factory. All purposed changes will require a
new name plate with appropriate ratings and new
product code to accommodate the recommended
part(s) changes.

–

7

PARTS "KIT" for FIELD REPAIR:

Contact your local Cashco, Inc., Sales Rep re sen­ ta tive with the Serial Number and Product code.
Identify the parts and the quantity required to repair
the unit from the "BOM" sheet that was provided
when unit was originally shipped.

NOTE: Those part numbers that have a quantity indicated

under "Spare Parts" in column "A” reflect minimum
parts required for inspection and rebuild, - "Soft
Goods Kit". Those in column “B” include minimum
trim replacement parts needed plus those "Soft
Goods" parts from column "A".

If the "BOM" is not available, refer to the cross­sectional drawings included in this manual for part
identification and selection.

A Local Sales Representative will provide quotation
for appropriate Kit Number, Price and Availability.

NOTE: In addition to ordering repair parts, it is recommended that a special double-posted spanner wrench

fitting be ordered for use in the main te nance of the ITA.

Double-Posted Spanner Wrench Fitting

Body Size Part Number

All A96-75-9-P0459-00

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be
construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to
modify or improve the designs or specifications of such product at any time without notice.
Cashco, Inc. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any
Cashco, Inc. product remains solely with the purchaser.

IOM-CA1/SA1

9

Opt-1 - Closing Cap

Figure 3:

Model CA1/SA1

Item No. Description

1 Adjusting Screw
2 Adjusting Screw Lock Nut
3 Closing Cap
4 Spring Chamber
5 Spring Follower
6 Range Spring
7 Nut Seal
8 Upper Diaphragm Plate
9

Diaphragm

*

10 Closing Cap Seal
11 Flange Bolt Nuts
12 Flange Bolt
13

‡

Piston-Guide Bearing
14 Thrust Washers
15

Cage O-ring Seal

*

16 Shim

Item No. Description

17 Cage Washer
18 Cage Cap Screw
19 Cage
20 Valve Plug
21

Seat Ring

*

22 Return Spring
23 Body
27 * Dynamic Side Seal

27.1

27.2

27.3

Cap Seal

*

O-ring Energizer

*

U-Cup Seal w/ Metal Energizer

*

28 * Diaphragm Seal

Recommended Repair Parts

*

‡

It is recommended that a special double-posted spanner

wrench fitting be ordered for use in the main te nance
of the ITA. To order, see NOTE in Section IX, Parts
Ordering Information.

10

IOM-CA1/SA1

ATEX 94/9/EC: Explosive Atmospheres and Cashco Inc. Regulators

NOTICE

Only for Product Codes wherein hazard
category ATEX has been selected.

These valves satisfy the safety conditions according to EN 13463-1 and EN 13463-5 for equipment group IIG 2 c.

Caution: Because the actual maximum temperature depends not on the equipment itself, but upon the fluid temperature, a
single temperature class or temperature cannot be marked by the manufacturer.

Specific Precaution to Installer: Electrical grounding of valve must occur to minimize risk of effective electrical discharges.

Specific Precaution to Installer: Atmosphere vent holes should be plugged to further minimize the risk of explosion.

Specific Precaution to Maintenance: The Valve Body/ Housing must be regularly cleaned to prevent buildup of dust deposits.

Specific Precaution to Maintenance: Conduct periodic Continuity Check between Valve Body/ Housing and Tank to minimize
risk of electrical discharges.

Attention: When repairing or altering explosion-protected equipment, national regulations must be adhered to. For maintenance
and repairs involving parts, use only manufacturer's original parts.

ATEX requires that all components and equipment be evaluated. Cashco pressure regulators are considered components.
Based on the ATEX Directive, Cashco considers the location where the pressure regulators are installed to be classified
Equipment-group II, Category 3 because flammable gases would only be present for a short period of time in the event of a leak.
It is possible that the location could be classified Equipment-group II, Category 2 if a leak is likely to occur. Please note that the
system owner, not Cashco, is responsible for determining the classification of a particular installation.

Product Assessment

Cashco performed a conformity assessment and risk analysis of its pressure regulator and control valve models and their
common options, with respect to the Essential Health and Safety Requirements in Annex II of the ATEX directive. The details
of the assessment in terms of the individual Essential Health and Safety Requirements, are listed in Table 1. Table 2 lists all of
the models and options that were evaluated and along with their evaluation.

Models and options not listed in Table 2 should be assumed to not have been evaluated and therefore should not be selected
for use in a potentially explosive environment until they have been evaluated.

Standard default options for each listed model were evaluated even if they were not explicitly listed as a separate option in the
table. Not all options listed in the tables are available to all models listed in the tables. Individual TB’s must be referenced for
actual options.

When specifying a regulator that is to be used in a potentially explosive environment one must review the evaluations in Table 1
and 2 for the specific model and each and every option that is being specified, in order to determine the complete assessment
for the unit.

A summary of the models and options found to have an impact on ATEX assessment due to potential ignition sources or other
concerns from the ATEX Essential Health and Safety Requirements, are listed below.

1. The plastic knob used as standard on some models, (P1, P2, P3, P4, P5, P7, 3381, 4381, 1171, and 2171) is a
potential ignition source due to static electricity. To demonstrate otherwise, the knob must be tested to determine
if a transferred charge is below the acceptable values in IEC 60079-0 Section 26.14 (See items 25, 27, and 28 in
Appendix A). Until the plastic knob has been shown to be acceptable, then either the metal knob option, or a preset
outlet pressure option is required to eliminate this ignition source (See items 45 and 64 in Tables).

2. The pressure gauges offered as options on a few of the regulator models (DA’s, P1-7, D, 764, 521), use a plastic
polycarbonate window that is a potential ignition source due to static electricity. To demonstrate that the gauges are
not a potential source of ignition, the gauges would need to be tested to determine if a transferred charge is below

IOM-CA1/SA1

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indicating the gauge is compliant with the ATEX Directive (See items 26, 27, and 28 in Appendix A). Until compliance
is determined, regulators should not be ordered with pressure gauges for use in potentially explosive environments.

3. Tied diaphragm regulators with outlet ranges greater than 100 psig should be preset to minimize the risk that improper
operation might lead to an outboard leak and a potentially explosive atmosphere (See item 6 in Table 1).

4. Regulators must be ordered with the non-relieving option (instead of the self-relieving option) if the process gas they are
to be used with is hazardous (flammable, toxic, etc.). The self-relieving option vents process gas through the regulator
cap directly into the atmosphere while the non-relieving option does not. Using regulator with the self- relieving option
in a flammable gas system could create an explosive atmosphere in the vicinity of the regulator.

5. Regulators with customer supplied parts are to be assumed to not have been evaluated with regard to ATEX and thus
are not to be used in a potentially explosive environment unless a documented evaluation for the specific customer
supplied parts in question has been made. Refer to Table 1 for all models and options that have been evaluated.

Product Usage

A summary of ATEX related usage issues that were found in the assessment are listed below.

1. Pressure regulators and control valves must be grounded (earthed) to prevent static charge build-up due to the flowing
media. The regulator can be grounded through any mounting holes on the body with metal to metal contact or the
system piping can be grounded and electrical continuity verified through the body metal seal connections. Grounding
of the regulator should follow the same requirements for the piping system. Also see item 30 in Table 1.

2. The system designer and users must take precautions to prevent rapid system pressurization which may raise surface
temperatures of system components and tubing due to adiabatic compression of the system gas.

3. Heating systems installed by the user could possibly increase the surface temperature and must be evaluated by the
user for compliance with the ATEX Directive. User installation of heating systems applied to the regulator body or
system piping that affects the surface temperature of the pressure regulator is outside the scope of this declaration and
is the responsibility of the user.

4. The Joule-Thomson effect may cause process gases to rise in temperature as they expand going through a regulator.
This could raise the external surface temperature of the regulator body and downstream piping creating a potential
source of ignition. Whether the Joule-Thomson effect leads to heating or cooling of the process gas depends on
the process gas and the inlet and outlet pressures. The system designer is responsible for determining whether the
process gas temperature may rise under any operating conditions. If a process gas temperature rise is possible under
operating conditions, then the system designer must investigate whether the regulator body and downstream piping
may increase in temperature enough to create a potential source of ignition.

The process gas expansion is typically modeled as a constant enthalpy throttling process for determining the temperature change.
A Mollier diagram (Pressure – Enthalpy diagram with constant temperature, density, & entropy contours) or a Temperature –
Entropy diagram with constant enthalpy lines, for the process gas, can be used to determine the temperature change. Helium
and hydrogen are two gases that typically increase in temperature when expanding across a regulator. Other gases may
increase in temperature at sufficiently high pressures.

Product Declaration

If the above issues are addressed by selecting options that do not have potential sources of ignition, avoiding options that
have not been assessed, and by taking the proper usage issue precautions, then Cashco regulators can be considered to be a
mechanical device that does not have its own source of ignition and thus falls outside the scope of the ATEX directive.

Cashco, Inc.
P.O. Box 6
Ellsworth, KS 67439-0006
PH [phone]
Fax. # [phone]
www.cashco.com
email: [email protected]

Printed in U.S.A. CA1/SA1-IOM

12

Cashco GmbH
Handwerkerstrasse 15
15366 Hoppegarten, Germany
PH [phone]
Fax. No. [phone]
www.cashco.com
email: [email protected]

Cashco do Brasil, Ltda.
Al.Venus, 340
Indaiatuba - Sao Paulo, Brazil
PH [phone]
Fax. No.
www.cashco.com
email: [email protected]

IOM-CA1/SA1